Method of making flexible molded articles of condensation products



- -the usual desirable characteristics of aldehyde condensation products with t e ad- Pat ented May 1,1928, 7

UNITED STATES 1568,445 PATENT OFFICE.

EDWARD L. AIKEN, OF EAST ORANGE, NEW JERSEY, ASSIGNOR T CAREOLOID PRO D- UGTS CORPORATION, OF NEWARK, NEW JERSEY, A COBIORATION OF NEW JERSEY.

METHOD or mmneernnxmnn monnnn narrows or oonnnnsa'rron rnonuc rs.

No Drawing. Application filed September 23, 1921, Serial No. 502,798. Renewed April 25,1924.

My invention relates particularly to compositions of matter which, while basically difierent therefrom, have somewhat the same lid - a a polyhydric' alcohol in which may be bent Another very advantageous feature of my methylene characteristics as phenol alhehyde condensation products but with marked advantages thereover; the invention also relates 'to the process of making such compositions of matter. My products may be prepared in a onestep. rocess, or when desirable in a multistep rocess, according to which I first roduceintermediate products and then nail products, and I generally prefer to have the multi-step process consist of two steps.

My products, both the intermediate and final, have the desirable characteristics of phenolic condensation products but differ therefrom in that they have highly desirable characteristics which it has been impossible to impart thereto. For example, I can produce an intermediate product which is so thinly fluid that it may be used alone for the impregnation of porous articles having very line pores, for example, wood, without the necessity of using a solvent for the urpose of thinning out the liquid sufiicient y so that it can penetrate into the fine pores as deeply as it may be desired.

Furthermore, by suflicient curing underproper conditions, I can produce a final infusible, insoluble (condensation roduct a eno ditional advantageous one that itis possible to control the hardness and flexibility of the same wherebyI can reduce finished articles ailmost double.

invention is that'my products maly be cured into their final insoluble, infusib e state by the mere application of heat, without the necessity of sub'ectin'g the: material to ressure, eit her in t e'one stage process w erein the final product is made in one operation from the phenylglyeeryl. compound and a dy, or. in a multi-stage process according to which I ppoduce intermediate products.- .7 'j- Bri fiysstated, my invention comprises makingTa condensationproduct either intermediate or final 'asinay be desired, by t n (lensing, with-a 'ody having available act ve methylene, a reaction product of henol lace oft e phenolic now generally u Homologs or' substitution productsot; phenolmay be used in i substitution products with any of the lieuthereof with good results; I prefer phenol, however, butintend the word phenolf,

as used in this description and in the claims to include the equivalent homologs or substitution products of phenol, as well as phenol itself, and Iintend theterm phenyl to include, similarly, radicals which are the E equivalents thereof; A number of the polyhydric alcohols maybe used for the preparationof the body which is to be condensed with the body having available active methylene, some of these polyhydric alcohols beng:--

Ethylene glycol O H, OH)

The use of glycerine results in a superior control of the hardness and flexibility, for which reason I prefer it to the other polyhydric alcohols, and I will describe my invention specifically with respect to glycerine.

The description relating to the preparation ofthe so-called glyceryl carbolates and the condensation thereof with active methylene compounds, relates equally well to compounds made by combining phenol or its homologs or substitution products with other polyhydric alcohols than glycerine, allowance being made'of course iorthe diflerent molecular a and equivalent weights in determining the reactin proportions. The term henylsubalky l compoundsi. as used in the c aims is intended to include compounds resulting from combining phenol or itshomologs or 0 y ydric alcohols, with the elimination 0 water.

- The compound made by combining phenol and lycerohmay have varying proportions of pfienyl radical to may possibly be 'glycery mono-, di-, or tricarbolate, or possibly mixtures' of these,

which will depend of course, on the proportions of'reagents used and also on the reaction conditions. I am not sure that the product which results from combining erol, and phenol is a glyceryl carbolate owever. It i s possible'that it maybe a mono-, cli-,;orctri-pheifyl glycerol or phenyl glyceryl alcohol, or possibly some other type ofcon po'und. Whatever the composition of thisproduct may be, it haspharacteriatica glyceryl radical, and

which difier materially from those of either glycerol or phenol, or a mere mixture thereof. For the purpose ofidentifying the substance I shall hereinafter call it phenylglyceryl body.

This phenyl glyceryl body, after having been freed from water, is condensed with some suitable body having available methylene, such for example, as formaldehyde, paraform, hexamethylenetetramin, etc

Such condensation produces an intermediate product which is liquid at normal temperature and is not resin-like at any time, although the degree of viscosity of this liquid is controllable and it may be made to have such viscosity as is most, suitable for the particular use, while the final product made therefrom, as hereinafter described, when fully cured, may have various degrees of hardness and flexibility, ran ing from a jelly-like substance to a cellu old-like substance. The intermediate liquid product may be used to impregnate cellular or fabric ma terials without the use of a solvent, if so desired, which is often the case, or it may oured into molds or it may be mixed wit any of the well known fillers such as wood flour, asbestos, cotton or wool fibers, silica, chalk, inert earths and other substances of like nature to form what may be called molding compounds, which may be formed into various shapes by any suitable method, such for example as forming in molds under pressure, and these may be subjected to heat. Or, when desired, it may be dissolved in .a suitable solvent as for example ethyl, methyl, or denatured alcohol, nitrohenzene, em, toa concentration suitable for use as a varnish or lacquer. The curing into the final stage is brought about by heat either with or without the application ofpressure.

My tri-carbolate may be prepared by mixing together three mols, that is 282 parts by weight, of phenol with one mol, that is 92 parts by weight of lcerine. This mixture is heated in a suitable vessel to a temperature of 110 C. When this temperature is reached hydrochloric acid gas is introduced through a tube leading to the bottom of the liquid, thegas bubbling up being allowed to pass out o the container either to the atmosphere or into another vessel wherein it may be recovered or reused. Suitable apparatus should be, provided; if the excess gas is allowed to pass to the atmosphere it may do so through a reflux condenser, or if it is to be recovered, the container may beclosed except for a connectionto a second vessel where the hydrochloric acid may be recovered. The mixture is treated with the hydrochloric acid gas until it is practically saturated, although this is not essential, as

only so much of the gas may be used-as is necessary to take up any free water present,

mes es done at a temperature of 110 0., until the compound tests neutral with an indicator. When neutral the compound will be found to be free from water when tested with anhydrous oupric sulphate, it is then allowed to cool to be subsequently condensed with the methylene body.

' The corresponding di-substance is prepared in the same manner as the tri-substance, except that the proportions of the reagents in this case would be two mols or 188 parts by weight of phenol, to one 11101, or 92 parts by weight of glycerine; and the preparation of illlBdIlOIlO-SllbSllfiIlOfi is also similar, except that the phenol and glycerine are .in e'qui-molecular proportions, that is 94:

parts by weight of phenol to 92 parts by weight of glycerine.

The above mentioned phenylglyceryl compound may alsobe made by using a concen trated solution or hydrochloric acid instead of the gas with very satisfactory results, the concentrated solution being used in the proportions of about 3 to 5% of the Weight of the reaction mass. The mixture may be heated at a temperature 01? 110 C. say inan open vessel, the Water being evaporated off with the hydrochloric acid.

The phenylglyceryl compounds may also be prepared without the use of any acid as a catalyst or dehydrating agent, by using the reagents in the proportions stated, and heating up to a temperature of from 120 to 125 (1, in a vessel provided with a reflux condenser. The removal of the water by this method takes about 30 hours with a quantity of about 500 grams whereas with the-use of the acid either in solution or as gas, the action is completed in about three hours for the same quantity.

()f the three methods for making my carbolates so far described, I prefer that according to which hydrochloric acid gas is passed intothe reaction mass.

These three methods are not the only ones according to which my phenylglyceryl compounds may be prepared. For example, I may mix phenol and glycerine in the various proportions above set forth and use anhydrous cupric sulphate to remove the water from the reaction mass. The amount of anhydrous cupric sulphate may be calculated on the basis of five moleculesof water of crystallization, but theexact amount of sulphate used is not important, provided that it be sufiicient to remove all of the water, as on excess of this deh drating agent generally has no harmful etl ect. The whole quantity of the anhydrous cupric sulphate may be added at onetime to the mixture, which is heated to, and maintained at a suitable temperature, for example, 110 C. at say atmospheric pressure, or it may be added in a number of smaller quantities; as the reaction proceeds the mass turns green, becoming very dark'in about two hours. The hydrated copper sulphate is filtered from the liquid product which has a black color,

very thin films being brownish black, 'par-' ticularly after standing for a few days. The color seems to be dissolved in the liquid, or at least extremely finely dispersed therein as it will pass through eight thicknesses of filter paper along withthe liquid, and no product made without an acid and also when,"

precipitate or coloring remains on the paper. When this compound is condensed with bodies having available methylene, it yields a final product having a jet black'color. All of these phenylglyceryl compounds are liquid and slightly viscous, and have a reddish orange color except thatmade with anhydrous cupric sulphate.

The various phenylglyceryl compounds differ from more mixtures of phenol and glycerine, which is water White in color. They change to a deep'reddlsh orange color as the reaction progresses in the case of the the acid is used. Furthermore, a mixture of phenol and glycerine in exact tri-phenylglyceryl proportions will, solidify at about 12 0., the tri-phenylglyceryl compound made without acid at about 0 C., the triphenylglyceryl compounds made with hydrochloric acid gas at about -5 'C., the di-phenylglyceryl compounds made with hydrochloric acid at about -7 C., and the di-phenylglycerylcompound madenvith hydrochloric acid gas below 7f. (3., at which temperature it shows no signs of solidifying. ,My mono-', dior tri-phenylglyeeryl compounds may, as stated above, be esters hav- \g the constitution indicated by s ti- H a t n where n equals 1, 2 or 3, or they may be of n01 an an alcoholic nature ,such as indicated by the formula (1.,H,,.,,(OH),(CJL), where 11 also probably equals 1, 2 or 3; or they may possibly have some other constitution. At any rate, they differ both physically and chemically from a mere mixture of glycerine and phenol.

Tests have shown that water is formed in theoretical proportions in the preparation of theahenylglyoeryl compoumh irom pheglyoerine. I

I he glycerylphenyl "compounds, whatever their constitution may be, are then condensed .with a available active process is preferred. I mix 100 parts b weight of the tri-phenylglyceryl compoun .23 parts by weight/of paraform, and 2 parts by 'wiaight of ammonium carbonate in a suitable vessel fitted with a reflux condenser mixture to about 60 to C. until the action of the ammonium carbonate becomes quiet. I then gradually increase the temperature to from to C. and maintain it 'and open to the atmosphere, and heat the thereat for several hours, the actual time depcnding ou the viscosityfldcsired in the resulting partially condensed liquid product.

-l/Vhen the viscosity has reached the degree desired, which may be ascertained by suitable tests, I allow: the partially condensed product to cool down to normalroom temperature. The product'is a more or less vlscous anhydrous liquld, insoluble in water but freely soluble in ethyl, methyl, or do natured alcohol, amyl alcohol, ether and chloroform. V

The ammonium carbonate is used as an alkaline catalyst or condenslng agent, and

may vary in amounts over a very Wide range.

I have found that about 9% M ammonium carbonate based on the amount of paraform used gives very satisfactory results, but this may be varied about 5% more or' less withv out detriment to the compound. When a less amount is used, the reaction is slower, and when larger amounts are used, it is accelerated. Man other catalysts, such form:-

ample as so iuln phenolate, calcium phe nolate, sodium hydrate, calcium oxide, po tassium carbonate, etc., may bedised with very good results; and the reaction may'even be carried on without the addition of any catalyst at all.

' It is more or; less immaterial how the reagents and catalysts are mixedfor example, the full. amount. of the aldehyde and catalyst may be mixed in with the phenylglyceryl compound at the start, or either one or both maybe added gradually without materially changing, theresults. A

Another -facto r ftlntt may be varied .over a considerable rangei's the temperature at which the reaction isQcaused to takefplaoe. In the example given, if the temperature is maintained at 70 to 75 6i tor three tofour hours,- a thin slightly viscous liquid' may be produced, which. issuitable for the impregnation of cellular and" fabric. materials without the use of any. solvent to reduce its viscosity and without heating. above room temperature. Should a more'v-iscous liquid ,or a semi-liquid similar to vaseline be desired, it is only necessary to continue the same heat for a longer time. The same results may be obtained by using a higher temperature for a shorter period of time, precautions being taken however, to maintain the temperature below that at which the heat developed by the reaction would cause the temperature to rise so rapidly as to cause the reaction to become violent. I have found that the temperature may with safety be allowed to rise gradually until itreaches atemperature of from 100 to 105 C., after the reaction has proceeded at about 70 (3. for about one hour, and at such higher temperature a thick viscous semi-liquid can be produced in a much shorter time than at the lower temperature.

I may state here that to produce the final product by the one-stage process the tem perature may be further increased, but this will be explained below. I may state as a general rule that any results obtained at any'given temperature may also be obtained at a lower or higher-temperature maintained respectively over a longer or shorter period of time.

p This completes the first stage of my two-- stage process and the product obtained thereby is the basic compound used in the second stage.

. My liquid or semi-liquid initial product has a variety of industrial applications.

The thin liquid may be used without a thinning solvent or without heating to thin it for the impregnation of all materials having a cellular structure, or of textile fabrics or substances of a porous nature. Avoidance of a solvent is important in the impregnation art for the reason that the dryingout or evaporation of the solvent leaves the impregnated material more or less porous. \Vith the use of my liquid prodnot the pores may be filled and they remain filled, leaving a substantially solid product. I am thus able to easily control the degree to which I desire to fill these pores; I can fill them completely by using my initial product without any solvent, or I can coat the inner walls of the pores to any desired thickness or thinnefs by impregnating the material with a solution of my initial product, the quantity of solvent to solute .depending upon the thickness of the coating desired, relatively more solvent being used for thinner coatings.

It has been impossible to impregnate porous materials, textiles, etc., with phenolic condensation puoducts without the use of a thinning solvent; for without the use of such a thinning solvent, the phenolic condensation products cannot be forced Well into the cellular substances to be impregnated. j

The use of my initial product thus makes it possible to fill the cells of the porous memes is possible to produce flexible impregnated.

materials andv articles, the flexibility of which is likewise controllable.

The partially condensed liquid or semiliquid may be dissolved in a suitable solvent and used as a varnish or lacquer, the viscosity being controlled by the amount of solvent used. The coating left after evaporation of the solvent has qualities heretofore unknown in lacquers or varnishes comprising phenolic condensation products for it may be converted or hardened into an insoluble, infusible but flexible coatin the flexibility of which may be controlle as desired.

My initial liquid or'semi-liquid condensation product may be. poured directly into suitable molds which may be either open or covered and may be converted into the final insoluble, infusible, but flexible product by mere heating, either with or without the use of pressure.

The partially condensed liquid or semiliquid may be mixed as is done with phenolic condensation products nvith various substances to form so-called molding compounds, such substances as rubber, wood flour, "asbestos, mica products, fibers, such as cotton, wool, etc., silica, graphite, cork, etc., each lending certain desirable characteristics to the compound. The partially condensed products in these mixtures act as binders, and when the mixture is subjected to,heat, are converted into an insoluble, infusible, flexible solid, firmly binding the whole into a unitary mass. These mixtures may be given various shapes by any suitable means or method, for example, by pressing in molds and may then be cured into the final product by the application of heat, either with or without pressure.

The partially condensed product itself alone, or mixed with other substances, or in solution, may be iven a suitable color. Dyes or pigments suc as ruby red, acetyl red, ultramarine blue, methyl blue, methyl green, chrome green, methyl violet, carbon or lamp black and a great many others may be used.

What may the process involves the further polymerization orcondensation of the initial product, above described, either as such, or mixed with other materials,'or when coated upon, or"impregnated within, various articles.

be called the second stage of 131i flexibility is considerably less, however, than that which will be observed by varying the lti . latter extendin amount of the available methylene used, this over a considerable range, as solid, infusi le, flexible products can be obtained by using amounts of paraform varying in quantity from 8 70, to 32% of the weight of the phenylglyc'eryl compound used; that is with the mono-compound, may use from 8 5% to 19% of paraform, with the di-compound from 11%% to 28% of paraform, and with the tri-compound from 13% to 32% of paraform, all calculated on the weight of the phenylglyceryl com ound and not on the total mlxture.

T e range of degrees of flexibility of the. final fully condensed product can thus be made to vary very materially and may range from a product similar to a stifi' jelly produced by the'smaller amounts of paraform, to a product similar in flexibility to tortoise shell when the larger amounts of paraform are used. I

The hardening or curing may be brough about by the mere application of. heat, and

1 pressure may be used or not, as desired.

Articles that have been impregnated with, or coated with, or-made of my partially con densed compound may be placed directly in a suitable oven or heating chamber that may,

-be heated by means of gas, steamor elec tricity and therein subjected to a temperature of about 100 to 105 (1, fora short nding more or less on the thickk e mass to be cured. --This time ordinarily may be about one to two hours. The temperature can then. be radually in creased to from 120 to 125 and maintained at this temperature until the partially condensed compound is fully and completely cured, or if-the r uirements of. the use of the finished article, o not demand complete ness of, t

. polymerization or condensation the articles may be removed from the heating chamber in], as the'applicati'on thereof makespos sible the application of .a higher'temperature at thebeginning of the operation whereby the total time of curing is lessened. The exact time necessary for the curing of an article made of, or containin my compounds cannot be definitely (state asthis will dedimensions of the article, but it may be stated as a general rule, that the lower the temperature, the longer the curing step will be.

I have used temperatures as high as 180 C. for curin and find that if this temperature be reac ed gradually it will havegno very great deleterious effect; but this tends to produce a rather hard oxidized surface which, however, might be desirable in some cases. Articles that have been varnished or lacquered with a solution of my initial product, should be allowed to stand in the air or gently heated to a temperature below the of removing the solvent. They may then be I placed in heating chambers and the final curing may be carried out as'previously described, which requires a comparatively short time on account of the compound being in the form of a very thin film.

When my initial product is poured into molds the curing process may be carried out as previously described, care being taken that the temperature is not allowed to be excessive at the start when curing at atmospheric pressure, in order to avoid the for- I mation of blisters on the surface, due to the violent formation of gas in the reaction. Whenmy initial product is mixed with other substances to form plastic molding com scribe-d, or they may be cured before removal from. the mold by heating it in any suitable manner, and the molds may be kept opened orclosed, thus subjecting the mass to atmospheric or greater pressure. When the molds are kept closed-temperatures as high as 175 C. may be used, and the curing may be accomplished in a relatively short 'pend on the temperature applied and the length of time, say in from five to ten minutes for small articles, and a proportionately longer time for larger ones, Or, if desire the molded articles may be partiallycured' in molds and thenremoved and finished in f an oven or heating chamber. prior thereto and allowed to cool to normal Sheets of paper or fabric, or a great many other-varieties of sheets may be surface coated with, immersed in, or impregnated with, my initial product. They may be passed through calendar or other rolls for the purpose of removing the excess of applied compound. The individual sheets may then be cured to the final state or a number of such sheets may be superposed and pressed'tm gether in suitable molds and so cured, as above described, thus forming sheet material having great strength, flexibility and resistance to chemicals.

I have set forth above a number of applications of my two-step process which is the one I generally prefer, but it is not to be considered as limited to the examples above described.

Briefly restated, my two-step process consists in reacting on my phenyllglyceryl compounds with available met ylene until a partial condensation or polymerization takes place, whereupon the reaction is stopped,

. other substances may or may not be incorpo- C. I then gradually increase the temperature up to 120 to 125 C., which ordinarily should take about two hours, and I maintain this last mentioned temperature until the curing is nearlyor wholly completed. The final product so obtained is a semi-transparent solid usually having reddish orange tint and it is insoluble and infusible and of various degrees of flexibility at normal temperatures, depending upon the proportionsof the various substances used; and it. js more flexible when hot than when cold. The final product obtained by either the one or two-stage process is exactly the same insofar as the condensation product itself is concerned but one of the advantages of the two-stage process is that substances may be mixed with the intermediate condensation product, all firmly bound together in one -'solid mass which possesses all the advantages of the well known phenolic condensation products with the brittleness of the latter eliminated, and with a wide range of flexibility at normal room temperature which may be perfectly controlled, as above set forth. My final product is insoluble in the common solvents and is furthermore infusible, but may be made softer and more.flexible by the'application' of heat, but it cannot be liquefied. It may be carbonized with suflicient heat but burns in a flame very slowly and it is, therefore, a very poor supporter of combustion and it is resistant to a great many chemicals. 4

In my co-pending applications,- filed of even date herewith, Serial Numbers 502,796 and 502,797., I claim the manufacture of the vpreliminary phenylglyceryl compound as well as the manufactureof my condensation product, and also the impregnation of articles therewith.

One of the essential features of my invention, asset forth herein above, is the concure it.

densation of the phenylglyceryl or phenylsubalkyl compound with available methyl ene; and by the terms essentially a phenylglyceryl body and essentially a phenylsubalkyl body I mean such body in at least commercially pure condition, and practically free "from accidentally presentreaction ingredients.

Having thus described my invention, what I claim as new and desire to secure byLetters-Patent, is

1. The process of making a flexible article which includes condensing essentially a phenylglyceryl body withavailable methyl ene to form an intermediate product, shaping said intermediate product without pressure, and heating t e shaped article to .2. The recess of making a flexible article which inc udes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, shaping.

said intermediate product without pressure, and heating the shaped article at atmospheric vpressure to cure it.

3. The process of making a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product,'shaping said intermediate product without pressure, and heating the shaped article at a temperature of about to C. to cure it.

4. The process of making a flexible article' which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, shaping said intermediate product withoutpressure, and heating the shaped article at a temperature of about 100 to 105 C. at atmospheric pressure, to cure it.

5. The process of making a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, shaping said intermediate product without pressure, heating the shaped article at a temperature of about 100 to 105 C., and then gradually increasing the temperature to, and main-.

taining it at about 120 to 125 C. I 6. The process of making a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, shap-' ing said intermediate product without pressure, heating theshaped article at atemperature of about 100 to 105 C. at atmospheric pressure, and then gradually increasing the temperature to, and maintaining it at, about 120 to 125 C. at atmospheric pressure.

7. The process of making a flexible'article ,which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, mixing filling material with said product, shaping it without pressure, and heating the shaped article to .cure it.

- filling material with said product, shaping it without pressure, and heating the shaped article at atmospheric pressure to cure it.

9. The process of making a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product; mixing filling material with said product, shaping it without pressure, and heating the shaped article at a temperature of about 100 to 105 C. to cure it.

10. The processof making a flexible article. which includes condensing essentlally a phe-' nylglyceryl body with" available methylene to form an intermediate product, mixing filling material with said product, shaping it without pressure, and heating the shaped article at about a temperature of 100 to 105 C. at atmospheric pressure to cure,it.

11. The process of making-a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate product, mixing filling material with said preduct, shaping it, without pressure, heating the shaped article at a temperature of about 100 to 105 (1., and then gradually increasing the temperature to, and'maintaining it at about 120 to 125 C.

12. The process of making a flexible article which includes condensing essentially a phenylglyceryl body with available methylene to form an intermediate. product, mixing filling material with saidproduct, shaping it witlio'ut pressure, heating the shaped ar- -ticle at a tem 'erature of about 100 to 105 C.,. at atmosp eric -pressure,'and then gradually increasing the temperature to and maintaining it atabout120 to 125 0., at

' atmospheric pressure.

13. The process of making a flexible article which includes condensing essentially a compound derived from the combination of'a phenol and a polyhydric alcohol with the elimination of water with available methylene to form an intermediate product; shaping said intermediate roduct without. pressure, and heating the siaped article to 15. The process of making a flexible article which includes condensing essentially a compound derived from the combination of a .phenol and a polyhydric alcohol with the eliminationof water with available methyl ene to form an intermediate product, shaping said intermediate product without pressure, and heating the shaped article at a temperature of about 100 to 105 C. to cure it.

16. The process of making a flexible-article nhich includes condensing essentially a compound derived from the combination of a phenol and a polyhydric alcohol with the elimination of Water with available methylene to form an intermediate product, shaping said intermediate product without pressure, and. heating theshaped article at a temperature of about 100 to 105 C. at atmospheric pressure, to cure it.

17. The process of makinga flexible article which includes condensing essentially a compound; derivedfrom the combination of a phenol and a polyhydric alcohol with the elimination of 'water with available methylene to form an intermediate product, shaping said intermediate product without pressure, heating'the shaped article at a temperature of about 100 to 105 C. and then gradually increasing the temperature to, and maintaining it at about 120 to 125 C.

18. The process of making a flexible article which includes condensing essentially a com pound derived from the combination of a phenol and a polyhydric alcohol with the elimination of water with available methylene to form an intermediate product, shaping said intermediate product without pressure, heating the shaped article at a temperatui'e of about ,to C. at atmospheric pressure,'and then gradually increasing the temperature to, and maintaining it at, about 120 to 125 (1, at atmospheric pressure.

19. The process of making a flexible article which includes condensing essentially a compound derived from the combination of'a phenol and'a polyhydrie alcohol ,with the elimination of water with available methylene to form an intermediate product, mixing filling material with said product without pressure, shaping it, and heating the Y shaped article to cure'itL I 20. The process of makingaflexlble article which includes condensing essentially a compound derived from the combination of a phenol and a polyhydric alcohol with the elimination of water with available methylene to form an intermediate product, mixingiilling material with said product without pressure, shaping-it, and heating the shaped article at atmospheric pressure to cure it. E

21. The process of making a flexible article a which includes condensing essentially a. compound derived from the combination of a phenol and a polyhydric alcohol with the elimination of water with available methylene to form an intermediate product, mix

' ing filling material with said product without pressure, shaping it, and heating the shaped article at a temperature of about 100 to 105 C. to cure it.

22. The process of making a flexible article which includes condensing essentially a compound derived from the combination of a phenol and a polyhydric alcohol with the elimination of water with available methylene to form an intermediate product, mix-.

ing filling material with said product Wlthr out pressure, shaping it, and heating the shaped article at about a temperature of 100 to 105 C. at atmospheric pressure to cure it. e v

23. The process of making a flexible article which includes condensing essentially a com- .pound derived from' the combination of a phenol and a polyhydric alcohol with the elimination of water with available methv mes es ylene to form an intermediate product, mixing filling material with said product without pressure, shaping it, heating the shaped article at a temperature of about 100 to 105 C;, and then gradually increasing the temperature to, and maintaining it at about maintaining it at abouti to C. at at- I mospheric pressure.

In testimony whereof, I affix my signature.

EDWARD L, AIKEN. I 

